Pakistan Steel Industry

The concern areas of this report are the steps involved in the production of iron and steel, the major types of emissions generated, legislation for controlling such pollution and the methods of managing these types of industrial waste. The industrial unit I have selected is Iron and Steel Industry in Pakistan (PAKISTAN STEEL MILLS). The iron and steel industry involves series of steps that generate vast volumes of air emissions, liquid effluents and solid wastes. In this report I will try to present an overview of waste management and pollution prevention opportunities of this industry. These opportunities are equally applicable to all the iron and steel industry.
History of Pakistan Steel Mills

The Pakistan Steel Mills is among the major Steel industries and is the stateowned producer of long rolled steel and heavy iron products in Karachi. The Pakistan Steel Mill is the country's largest industrial undertaking having a production capacity of 1.1 million tonnes of steel. Its unloading and conveyor system at Port Qasim is the third largest in the world. After independence in 1947, Pakistan realized that industrial and economical development would be impossible without the possession of a self reliant iron and steel making plant. The dependence on imports would cause serious setbacks to the state due to which Government of Pakistan decided that the Karachi Steel Project should be sponsored in the public sector.

Location and site

Pakistan Steel is located at a distance of 40 km Southeast of Karachi at Bin Qasim near Port Muhammad Bin Qasim. It was found to be an ecologically preferable location, alongside a tidal creek and having a wind direction away from the city of Karachi.

Social obligations
Pakistan Steel Mills, besides its core activities, has done a lot in making the environment in and around Pakistan Steel green and beautiful through the addition of three unique projects: the Quaid-I-Azam Park, The Quaid-I-Azam Cricket Park and the Quaid-I-Azam Beach. Pakistan Steel is also on its way to establish Quaid-I-Azam National Park over a vast area of 400 acres (1.6 km2) adjacent to Steel Town which shall be a tremendous contribution in the development of the environment.

Properties of Iron and steel

Iron is tough, tough to work and shape, and tough in its application. But while iron metal is difficult to make, iron ore is easy to find. Iron is one of the most abundant elements in the earth's crust (about 5% by weight. The producers convert these raw materials in to furnished products by using extensive energy following strick specifications. Steel is an alloy of iron usually containing less than 1% carbon. It is used most frequently in the automotive and construction industries. Steel can be cast into bars, strips, sheets, nails, spikes, wire, rods or pipes as needed by the intended user. The iron and steel sector is still one of the nation's biggest energy users, and still one of the biggest emitters of criteria air pollutants and greenhouse gases, of all industrial sectors. Industry profile Iron and steel making processes proceed through a series of successive refinements. Generally speaking, the rapid the process, the greater the environmental impact. The process begins with extraction of iron from its ore. Finally, the crude material is purified and alloyed. Environmental challenges have to be faced during this process.

Iron making

Iron making refers to the reduction of metallic iron from the oxide form in which the element is found in nature. The product, called pig iron, contains a high percentage of carbon, along with various other impurities. The process is carried out in a blast furnace, a large vertical reaction vessel. The temperature inside the furnace is extremely high .The furnace is operated in continuous mode. As a result of the intense heat, the use of any kind of mechanical devices for conveying or mixing materials would create problems. So the blast furnace must rely on gravity and convection to establish the needed flows of reactants and products. Chunks of ore and coke (along with a limestone flux, to help remove impurities from the molten iron) are added to the top of the vessel, which move slowly downwards. Hot air is introduced through nozzles around the bottom of the reactor, and the gases flow upward. The air when present in sufficient quantities to burn carbon partially but not completely gets changed into an aggressively reducing medium, carbon monoxide. This molecule is sufficiently hungry for oxygen that it can strip it from the iron oxide ore, leaving reduced molten iron to flow down toward the bottom of the furnace, where it can be periodically tapped off. As the solid material (unreduced ore and unburned fuel) moves down through the furnace, it must remain sufficiently permeable to allow the gases to move upward through it. The chunks must be strong enough to resist being crushed to powder by the weight of the material above it. Environmental consequences

A number of environmental consequences flow from these design constraints. The furnace itself is an abundant source of carbon monoxide (a criteria air pollutant), that can leak from the furnace at various openings. There are numerous ways to generate particulate emissions, one of the most important occurring during the tapping of molten iron. The blast furnace also generates large quantities of slag -impurities that float on the metal, and are skimmed off. Much of that material can be used in the construction industry (in roadbeds, for example) It is interesting to compare the implication of these new developments in iron making technology for energy efficiency with the implications for environmental impact. . The inputs are essentially the same. All of the volatiles in the coal still have to go somewhere. The environmentally acceptable alternatives for them include recovery and reuse, or conversion to less toxic forms. Much of the volatile fraction is hydrocarbon pollutants, which can be oxidized to carbon dioxide (a greenhouse gas, but somewhat less objectionable in terms of toxicity or ground-level ozone forming potential).
Steelmaking

Iron as it emerges from the blast furnace contains about 4% carbon -- too much for most applications. Steelmaking is the term applied to the last stage of refinement in composition of the end product. In addition to removing the carbon and other impurities, the steelmaking process also involves the addition of various elements to give desire properties to steel. There are two main processes for making steel in current use. Basic Oxygen Furnace (BOF) The Electric Arc Furnace (EAF).

Environmental impacts and risks

Air emissions include particulates. Blast furnace iron making generates large quantities of sulfur and nitrogen oxides and carbon monoxide Wastewater from cokemaking has high contaminant levels, requiring extensive removal and treatment before disposal. Solid wastes from this industry present problem. The sector is a very large consumer of energy, and as such is a major contributor to greenhouse gas emissions.

Quantitative impact data

Greenhouse Gas Estimates . According to the calculations, the iron

and steel sector (NAICS code 331111) was responsible for 224.8 Tg CO2 equivalent (1 Tg, or teragram = 1 million metric tons), of which 157.1 Tg was due to fuel consumption, and 67.7 Tg to non-fuel uses (such as the release of carbon dioxide from the use of limestone, calcium carbonate, as a flux material). This makes the sector one of the most significant contributors to greenhouse gas emissions of all industry sectors. About 100 gallons of wastewater are generated for every ton of coke produced. Risks

The most significant direct risks posed by the iron and steel sector are in the air quality area, primarily as a source of fine particles.The sector is also a major contributor to nitrogen oxide and volatile organic compound (VOC) emissions. Among the criteria air pollutants, these categories are the most direct contributors to ozone generation.
Effects of existing and future regulations on impacts

Among all the environmental standards that apply to the iron and steel industry, air quality regulations have had the most profound effect on the sector air emissions regulations.

Information sources

http://www.steel.org/learning/howmade/howmade.htm http://www.oit.doe.gov/steel/ http://www.oit.doe.gov/steel/profile.shtml http://www.eia.doe.gov/emeu/mecs/iab/steel/index.html http://www.oit.doe.gov/steel/pdfs/steel_profile.pdf http://www.oit.doe.gov/steel/roadmap.shtml http://www.steellinks.com/

WEBSITE NO 3 The Steel Making Industry The process of steelmaking has undergone many changes based on technological atmosphere. In the 1950s and 1960s, demand for high quality steel encouraged the steelmaking industry to produce large quantities. Integrated steel plants produce steel by refining iron ore in several steps and produce very high quality steel with well controlled chemical compositions to meet all product quality requirements. The furnaces used in integrated plants were very efficient; however, the common production practices needed to be improved. By keeping blast furnaces continually feed with iron ore, heat is used more efficiently. As environmental concerns have gained importance in the 1980s and 1990s, regulations have become more strict, again changing the steelmaking industry. In 1995, compliance with environmental requirements was estimated to make up 20-30% of the capital costs in new steel plants.The competition has forced steelmaking facilities to reduce expenses and increase quality. To meet these changing needs, just-in-time technology has become more prominent and integrated steel plants are being replaced with smaller plants, called mini-mills that rely on steel scrap as a base material rather than ore market.

Steel Production from Iron Ore

Steel production at an integrated steel plant involves three basic steps. The heat source used to melt iron ore is produced.

Next the iron ore is melted in a furnace. Finally, the molten iron is processed to produce steel.

Cokemaking Coke is a solid carbon fuel ,used to melt and reduce iron ore. Coke production begins with pulverized, bituminous coal. The coal is fed into a coke oven which is sealed and heated to very high temperatures for 14 to 36 hours. Heat is frequently transfered from one oven to another to reduce energy requirements. After the coke is finished, it is moved to a tower where it is cooled with water spray. Once cooled, the coke is moved directly to an iron melting furnace or into storage for future use. Ironmaking During ironmaking, iron ore, coke, heated air and limestone or other fluxes are fed into a blast furnace. Limestone or other additives may be added to react with and remove the acidic impurities, called slag, from the molten iron. The limestone-impurities mixtures float to the top of the molten iron and are skimmed. Steelmaking with the Basic Oxide Furnace (BOF) Molten iron from the blast furnace is sent to a basic oxide furnace, which is used for the final refinement of the iron into steel. High purity oxygen is blown into the furnace and combusts carbon and silicon in the molten iron. The basic oxide furnace is fed with fluxes to remove any final impurities. Alloy materials may be added to improve the characteristics of the steel. The resulting steel is most often cast into slabs, beams or billets. Different types of pollution result from the different steps in steel production. Below, the pollution sources and the possible pollution prevention opportunities are discussed for each process. Pollution Sources and Prevention for Cokemaking Coke production is one of the major pollution sources from steel production. Air emissions such as coke oven gas, naphthalene, ammonium compounds, crude light oil, sulfur and coke dust are released from coke ovens. Emissions control equipment can be used to capture some of the gases. Some of the heat can be captured for reuse in other heating processes. Other gases may escape into the atmosphere.

The Steel Making Process (EPA, 1995) Water pollution comes from the water used to cool coke after it has finished baking. Sufficient amount of water becomes contaminated with coke breezes and other compounds. While the volume of contaminated water can be great, quenching water is fairly easy to reuse. Coke breezes and other solids can usually be removed by filtration. The resulting water can be reused in other manufacturing processes or released. Reducing Coke Oven Emissions Pollution associated with coke production is best reduced by decreasing the amount of coke used in the iron melting process. The smaller the volume of coke produced, the smaller the volume of air and water emissions. One fairly economical method of reducing coke oven pollution is to reduce the levels of coke used in blast furnaces. A portion of the coke can be replaced with other fossil fuels without retrofitting the furnace. Pulverized coal can be substituted for coke at nearly a 1:1 and can replace 25 - 40% of coke traditionally used in furnaces .Pulverized coal injection is used worldwide to reduce coke use and, thus, coke emissions. But it may not be possible to substitute pulverized coal for coke in the production of high quality steel because it would cause accumulation of unburnt particles in furnace. So pulverized coal injection may affect the final steel products. Other alternative fuels such as natural gas, oil or tar/pitch can be used to replace coke using similar process modifications. The reduction in emissions is proportional to the reduction in coke use. A third method for reducing coke oven emissions is the Davy Still Autoprocess. The process uses water to remove ammonia and hydrogen sulfide from coke oven emissions prior to cleaning of the oven. Pollution Sources and Prevention in Ironmaking Slag, the limestone and iron ore impurities collected at the top of the molten iron, make up the largest portion of ironmaking by-products. Sulfur dioxide and hydrogen sulfide are volatized and captured in air emissions control equipment and the remaining slag is sold to the construction industry. While this is not a pollution prevention technique, the solid waste does not reach landfills.

Blast furnace flue gas is also generated during ironmaking. This gas is cleaned to remove particulates and other compounds, allowing it to be reused as heat for coke furnaces or other processes. Cleaning gas for reuse can produce some air pollution control dust and water treatment plant sludge, depending on the method used. Steel Production from Scrap Metals Steelmaking from scrap metals involves melting scrap metal, removing impurities and casting it into the desired shapes. Electric arc furnaces (EAF) are often used.The EAFs melt scrap metal in the presence of electric energy and oxygen. The process does not require the three step refinement as needed to produce steel from ore. Production of steel from scrap can also be economical on a much smaller scale. Frequently mills producing steel with EAF technology are called mini-mills. Pollution Sources and Material Recovery Gaseous emissions and metal dust are the most prominent sources of waste from electric arc furnaces. Gaseous emissions are collected and cleaned, producing EAF dust or sludge. The remaining gas contains small quantities of nitrogen oxide and ozone and is usually released. The EAF dust or sludge composition varies depending on the type of steel being manufactured. After the heavy metals have been removed, the dust is composed primarily of iron and iron oxides and may be remelted. If the metal content is sufficient, the dust can be reused in the blast furnaces. If it is not sufficient, the dust can be sold to other industries for use as raw materials in bricks, cement, sandblasting or fertilizers. Steel Forming and Finishing After the molten metal is released from either the BOF, EAF it must be formed into its final shape and finished to prevent corrosion. Traditionally, steel was poured into convenient shapes called ingots and stored until further shaping was needed. After the steel has cooled in its mold, continued shaping is done with hot or cold forming. Hot forming is used to make slabs, strips, bars or plates from the steel. Heated steel is passed between two rollers until it reaches the desired thickness. Cold forming is used to produce wires, tubes, sheets and strips. In this process the steel is passed between two rollers, without being heated, to

reduce the thickness. The steel is then heated in an annealing furnace to improve the ductile properties. Cold rolling is more time consuming, but is used because the products have better mechanical properties, better machinability, and can more easily be manipulated into special sizes and thinner gauges. After rolling is completed, the steel pieces are finished to prevent corrosion and improve properties of the metal. Pollution Sources and Prevention from Steel Forming The primary wastes produced in the metal forming process include contact water, oil, grease, and mill scale. All are collected in holding tanks. The scale settles out and is removed. It can be reused in sintering plants or, if the metal content is sufficient, may be sold as a raw material elsewhere. The remaining liquid leaves the process as waste treatment plant sludge. As the waste results in a small portion of pollution produced by steelmaking, pollution prevention and process modification opportunities are not a priority.

References
Chatterjee, Amit. "Recent Developments in Ironmaking and Steelmaking." Iron and Steelmaking. 22:2 (1995), pp. 100-104. Frukawa, Tsukasa. "5000 Daily Tons of Direct Iron-Ore Smelting by 2000." New Steel. 10:11 (November, 1994), pp. 36-38. McManus, George, ed. "Replacing Coke With Pulverized Coal." New Steel. 10:6 (June, 1994), pp. 40-42. Ritt, Adam. "DRI comes to the Gulf Coast." New Steel. January, 1996, pp. 54-58. Strohmeier, Gerolf, and John Bonestell. "Steelworks Residues and the Waelz Kiln Treatment of Electric Arc Furnace Dust." Iron and Steel Engineering. April, 1996, pp. 87-90. U.S. Department of Commerce. 1992 Census of Manufacturers Blast Furnaces, Steel Works and Rolling and Finishing Mills. 1992. USEPA. "Profile of the Iron and Steel Industry." EPA/310-R-95-010, U.S. Environmental Protection Agency. Washington, D.C., September 1995.

WEBSITE No 3

ENVIRONMENT The steel industry should have a strict environmental policy. They should be commit for the continuous improvement of our environmental
performance. Every industry should take their environmental responsibilities seriously and environmental protection should be integrated in all their business and process activities. As far as Pakistan Steel mills is concerned, in the past two years they followed an active reforestation program within and exceeding its 20,000 acres of responsibility. They are continuously setting new targets for waste reduction and pollution prevention. They have carried out extensive work in water recirculation and treatment and have improved the treatment of fresh water supply feed to lakes and reservoirs for the benefit of our local communities.

Health & Safety

Pakistan Steel adheres to a strict, health and safety policy. We are committed to providing a safe and healthy working environment to all our employees and work continuously to incorporate safety in design. Our drive in the achievement of a safe working environment with safe working practices has recently awarded us with OHSAS 18001 accreditation. We however, Endeavour to continue our work in the field of safety and continuously push safety practices and safety education and training across the whole workforce.

The management at Pakistan Steel is fully committed to providing a high level of social accountability to all its workforce. It follows the philosophy that Pakistan Steel's success comes from its people and the needs of the people are inseparable from the needs of the organization.